Multifunctional face masks and fabricating methods and applications of same

ABSTRACT

The invention relates to multifunctional face masks/coverings, compositions used in the multifunctional face masks, alternatively solutions of the compositions, manufacturing methods. The multifunctional face mask includes at least one composite layer comprising at least one layer of a nonwoven material and a composition coupled to the at least one layer of the nonwoven material such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals. The composition comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority to and the benefit of, pursuant to 35 U.S.C. § 119(e), U.S. Provisional Patent Application Ser. No. 62/990,235, filed Mar. 16, 2020, which is incorporated herein in their entirety by reference.

FIELD

The disclosure relates generally to material science, and more particularly, to multifunctional face masks and coverings, compositions used for the multifunctional face masks and coverings, and manufacturing methods of the multifunctional face masks and coverings.

BACKGROUND

The background description provided herein is for the purpose of generally presenting the context of the invention. The subject matter discussed in the background of the invention section should not be assumed to be prior art merely as a result of its mention in the background of the invention section. Similarly, a problem mentioned in the background of the invention section or associated with the subject matter of the background of the invention section should not be assumed to have been previously recognized in the prior art. The subject matter in the background of the invention section merely represents different approaches, which in and of themselves may also be inventions.

For over a century, face masks or coverings including their materials and methods of manufacture and use for face coverings and other personal protective equipment (PPE) by design are mainly for passive physical filtrations and blockings of pathogenic airborne particles and chemicals. However, these conventional materials and methods of manufacture and use have drawbacks and limitations as pathogenic airborne particles and chemicals may collect on face coverings and other PPEs and remain viral thereon. Hence, there is a longstanding and compelling need for improving the body of known materials and methods, and the materials surface functions, for improving the filter-like face mask materials and to mass-produce the face masks for protecting humans (and household mammals) effectively from being affected by airborne viruses, bacteria, pollens, and hazardous chemicals at an ultralow cost. The mass-productions of the long-overdue face masks is highly urgent due to the coronavirus pandemics worldwide in these days.

SUMMARY

The objectives of this invention are to disclose a multifunctional face mask, and a composition, alternatively a solution of the composition, for improving the coatings and coating methods to upgrade the chemical functions of the face masks and other PPEs and to mass-produce the multifunctional face mask for protecting humans (and animals/pets) actively and chemically at an ultralow cost, besides passively and physically like that in many of the commercially available surgical masks, N95 masks, and KN95 masks.

In one aspect, the invention relates to a multifunctional face mask comprising at least one composite layer comprising at least one layer of a nonwoven material and a composition coupled to the at least one layer of the nonwoven material such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals, wherein the composition comprises food-grade adhesives, biodegradable adhesives, antivirus salts' anions and/or cations, antifreeze agents, moisture-holding substances, or a combination of them.

In one embodiment, the food-grade adhesives comprise mono-, di-, oligo- and poly-saccharides-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms (i.e., 100% in concentration), or mixtures with a variety of mixing ratios, ranging from 99% to 1% for every components.

In one embodiment, biodegradable adhesives comprise polyols (i.e., small-chain carbohydrates), poly-alcohols (also called sugar alcohols, typically derived from sugars, containing one hydroxyl group attached to each carbon atom, such as), mono- and di- and oligo- and poly-saccharides- or starches-based adhesives, protein-based adhesives (such as glutens, collagens, etc.), or a combination of them.

In one embodiment, the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In one embodiment, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

In one embodiment, the antivirus salts comprising Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, and/or Zn²⁺ are in pure forms, or mixtures with a variety of mixing ratios, either with the same cations but different anions or the same anions but different cations.

In one embodiment, the nonwoven material comprises fibers of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them.

In one embodiment, the fibers have fiber-lengths, fiber-diameters, and/or fiber-surface chemical functional groups that are variable over a range in either the pure forms or the mixed forms.

In one embodiment, the antivirus salts and the food-grade adhesives are mixed with the antifreeze agents such as water-soluble salts and the moisture-holding salts such as the water-soluble salts over a range of mixing ratios.

In one embodiment, the composition is coated on, and/or impregnated in the at least one layer of the nonwoven material.

In one embodiment, the at least one composite layer is adapted concertedly to denature nanospike proteins on the coronavirus surface and to wrap the coronavirus nanospike surface with the adhesives to make the nanospike no longer functional.

In one embodiment, the multifunctional face mask further comprises at least one inner layer and at least one outer layer, wherein the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.

In one embodiment, each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed by lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven materials that are synthetic (i.e., manmade) or natural materials.

In one embodiment, the exterior surface of the at least one outer layer is adapted to be super-hydrophobic and electrostatically charged for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from sticking on or penetrating through the at least one outer layer.

In another aspect, the invention relates to a method of manufacturing a multifunctional face mask comprising providing a solution containing a composition, wherein the composition comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them; and applying the solution to at least one layer of a nonwoven material so that the composition is coated on, and/or impregnated in the at least one layer of the nonwoven material to form at least one composite layer therewith, such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals.

In one embodiment, said providing the solution comprises mixing the composition with water over the wide range of concentrations from 1% to 99%.

In one embodiment, said applying the solution to the at least one layer of the nonwoven material comprises spraying the solution to the at least one layer of the nonwoven material; or soaking the at least one layer of the nonwoven material in the solution.

In one embodiment, the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.

In one embodiment, the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.

In one embodiment, the anions of the antivirus salts being mixed in the adhesive(s) comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In one embodiment, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

In one embodiment, the nonwoven material being coated with the adhesives and salts comprises fibers of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them.

In one embodiment, the method further comprises assembling the at least one composite layer with at least one inner layer and at least one outer layer, such that the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.

In one embodiment, each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed of lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven material.

In one embodiment, the method further comprises applying the solution to the exterior surface of the at least one outer layer for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from sticking on or penetrating through the at least one outer layer.

In yet another aspect, the invention relates to a composition used in a multifunctional face mask for trapping and/or deactivating one or more of airborne virus, bacteria, pollen particles and hazardous chemicals. The composition comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them.

In one embodiment, the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.

In one embodiment, the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.

In one embodiment, the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In one embodiment, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

These and other aspects of the disclosure will become apparent from the following description of the preferred embodiment taken in conjunction with the following drawings, although variations and modifications therein may be effected without departing from the spirit and scope of the novel concepts of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate one or more embodiments of the disclosure and together with the written description, serve to explain the principles of the disclosure. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment.

FIG. 1 shows schematic of multiple layers of a multifunctional face mask according to embodiments of the invention.

DETAILED DESCRIPTION

The disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the disclosure are shown. The disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout.

The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Certain terms that are used to describe the disclosure are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the disclosure. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting and/or capital letters has no influence on the scope and meaning of a term; the scope and meaning of a term are the same, in the same context, whether or not it is highlighted and/or in capital letters. It will be appreciated that the same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification, including examples of any terms discussed herein, is illustrative only and in no way limits the scope and meaning of the disclosure or of any exemplified term. Likewise, the disclosure is not limited to various embodiments given in this specification.

It will be understood that when an element is referred to as being “on”, “attached” to, “connected” to, “coupled” with, “contacting”, etc., another element, it can be directly on, attached to, connected to, coupled with or contacting the other element or intervening elements may also be present. In contrast, when an element is referred to as being, for example, “directly on”, “directly attached” to, “directly connected” to, “directly coupled” with or “directly contacting” another element, there are no intervening elements present. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” to another feature may have portions that overlap or underlie the adjacent feature.

It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Thus, a first element, component, region, layer or section discussed below can be termed a second element, component, region, layer or section without departing from the teachings of the disclosure.

Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top”, may be used herein to describe one element's relationship to another element as illustrated in the FIGURES. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation shown in the FIGURES. For example, if the device in one of the FIGURES is turned over, elements described as being on the “lower” side of other elements would then be oriented on the “upper” sides of the other elements. The exemplary term “lower” can, therefore, encompass both an orientation of lower and upper, depending on the particular orientation of the FIGURE. Similarly, if the device in one of the FIGURES is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.

It will be further understood that the terms “comprise(s)” and/or “comprising”, or “include(s)” and/or “including” or “has (have)” and/or “having” or “contain(s)” and/or “containing” when used in this specification specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.

This disclosure describes various elements, features, aspects, and advantages of various embodiments, formulations, configurations, and arrangements of nanomaterial compositions, and methods for the same thereof. The disclosure and the new hierarchical nanochemical bonding science are not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. It is to be understood that certain descriptions of the various embodiments and such configurations and arrangements thereof have been simplified to illustrate only those elements, features and aspects that are relevant to a more clear understanding of the disclosed embodiments, while eliminating, for purposes of brevity or clarity, other elements, features and aspects. Any references to “various”, “certain”, “some”, “one”, or “an” when followed by “embodiment”, “configuration”, “example”, or “arrangement” generally means that a particular element, feature or aspect described in the example is included in at least one embodiment. The phrases “in various”, “in certain”, “in some”, “in one”, “in an”, “in a further”, or similar when followed by “embodiment”, “configuration”, “example”, or “arrangement” may not necessarily refer to the same embodiment. Furthermore, the phrases “in one such” or “in this” when followed by “embodiment”, “configuration”, “example”, or “arrangement”, while generally referring to and elaborating upon a preceding embodiment, is not intended to suggest that the elements, features, and aspects of the embodiment introduced by the phrase are limited to the preceding embodiment; rather, the phrase is provided to assist the reader in understanding the various elements, features, and aspects disclosed herein and it is to be understood that those having ordinary skill in the art will recognize that such elements, features, and aspects presented in the introduced embodiment may be applied in combination with other various combinations and sub-combinations of the elements, features, and aspects presented in the disclosed embodiments. The conjunction “or” is generally used as inclusive, synonymous with the conjunction “and/or”, permitting either or more of two or more alternatives, but not to require that multiple alternatives exist.

It is to be appreciated that persons having ordinary skill in the art, upon considering the descriptions herein, will recognize that various combinations or sub-combinations of the various embodiments and other elements, features, and aspects may be desirable in particular implementations or applications. However, because such other elements, features, and aspects may be readily ascertained by persons having ordinary skill in the art upon considering the description herein, and are not necessary for a complete understanding of the disclosed embodiments, a description of such elements, features, and aspects may not be provided. As such, it is to be understood that the description set forth herein is merely exemplary and illustrative of the disclosed embodiments and is not intended to limit the scope of the disclosure as defined solely by the claims.

As used herein, “around”, “about”, “substantially” or “approximately” shall generally mean within 20 percent, preferably within 10 percent, and more preferably within 5 percent of a given value or range. Numerical quantities given herein are approximate, meaning that the terms “around”, “about”, “substantially” or “approximately” can be inferred if not expressly stated. Any numerical range recited herein includes all values from the lower value to the upper value. For example, if a concentration range is stated as 1% to 50%, it is intended that values such as 2% to 40%, 10% to 30%, or 1% to 3%, and the like, are expressly enumerated in this specification. These are only examples of what is specifically intended, and all possible combinations of numerical values between and including the lowest value and the highest value enumerated are to be considered to be expressly stated in this application. Numbers modified by the term “about” are intended to include +/−10% of the number modified.

The illustrations of arrangements described herein are intended to provide a general understanding of the structure of various embodiments, and they are not intended to serve as a complete description of all the elements and features of the embodiments described herein. While the present disclosure generally describes the inventive concept, those having skill in the art will appreciate that the embodiments, and disclosures described herein may find application in many industries. Other arrangements may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. FIGURES are also merely representational and may not be drawn to scale. Certain proportions thereof may be exaggerated, while others may be minimized. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

Thus, although specific arrangements have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific arrangement shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments and arrangements of the disclosure. Combinations of the above arrangements, and other arrangement not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description. Therefore, it is intended that the disclosure not be limited to the particular arrangement(s) disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments and arrangements falling within the scope of the appended claims.

The description below is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the disclosure.

The mass-productions of personal protective equipment (PPE) such as face masks/coverings are urgent because of the ongoing COVID-19 pandemics worldwide since the late 2019 due to the coronavirus rapid mutations. In this invention, the novel composition and disposable multifunctional face masks for both large-scale manufacturing and customers' personal use are feasible on a wide variety of conventional face-coverings made of nonwoven and woven textiles, membranes, and filters of freestanding membranes and textiles of many types. In addition, the use of composition as ingredients in or coatings on other PPE and non-PPE products is feasible on a wide variety of these materials.

In one aspect of the invention, the multifunctional face mask comprises at least one composite layer comprising at least one layer of a nonwoven material and a composition coupled to the at least one layer of the nonwoven material such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals, wherein the composition comprises food-grade adhesives, biodegradable adhesives, antivirus salts' anions and/or cations, antifreeze agents, moisture-holding substances, or a combination of them.

In one embodiment, the food-grade adhesives comprise mono-, di-, oligo- and poly-saccharides-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms (i.e., 100% in concentration), or mixtures with a variety of mixing ratios, ranging from 99% to 1% for every components.

In various embodiments, the biodegradable adhesives comprise polyols (i.e., small-chain carbohydrates), poly-alcohols (also called sugar alcohols, typically derived from sugars, containing one hydroxyl group attached to each carbon atom), mono- and di- and oligo- and poly-saccharides- or starches-based adhesives, protein-based adhesives (such as glutens, collagens, etc.), or a combination of them. In some embodiments, the polyols comprise an organic compound containing multiple hydroxyl groups. In some embodiments, the polyols comprise molecules with more than two hydroxyl groups is a polyol. In some embodiments, the polyols may contain other functional groups.

In various embodiments, the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions. The mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In various embodiments, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

In various embodiments, the antivirus salts comprising Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, are in pure forms, or mixtures with a variety of mixing ratios, either with the same cations but different anions or the same anions but different cations.

In various embodiments, the nonwoven material comprises nonwoven fabric of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them. The nonwoven fabric is a fabric-like material made from staple fibers (short) and long fibers (continuous long), bonded together by chemical, mechanical, heat or solvent treatment.

In various embodiments, the fibers have fiber-lengths, fiber-diameters, and/or fiber-surface chemical functional groups that are variable over a range in either the pure forms or the mixed forms.

In various embodiments, the antivirus salts and the food-grade adhesives are mixed with the antifreeze agents such as the water-soluble salts disclosed in the disclosure, and the moisture-holding salts such as the water-soluble salts disclosed in the disclosure over a range of mixing ratios.

In various embodiments, the composition is coated on, and/or impregnated in the at least one layer of the nonwoven materials that are manmade (i.e., synthetic) or natural.

In various embodiments, the at least one composite layer is adapted concertedly to denature nanospike proteins on the coronavirus surface and to wrap the coronavirus nanospike surface with the adhesives to make the nanospike no longer functional.

In various embodiments, the multifunctional face mask further comprises at least one inner layer and at least one outer layer, wherein the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.

In various embodiments, each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed of lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven material.

In various embodiments, the exterior surface of the at least one outer layer is adapted to be super-hydrophobic and electrostatically charged for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from sticking on or penetrating through the at least one outer layer.

In another aspect of the invention, the method of manufacturing a multifunctional face mask comprises providing a solution containing a composition, wherein the composition comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them; and applying the solution to at least one layer of a nonwoven material so that the composition is coated on, and/or impregnated in the at least one layer of the nonwoven material to form at least one composite layer therewith, such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals.

In various embodiments, said providing the solution comprises mixing the composition with water over the wide range of concentrations from 1% to 99%.

In various embodiments, said applying the solution to the at least one layer of the nonwoven material comprises spraying the solution to the at least one layer of the nonwoven material; or soaking the at least one layer of the nonwoven material in the solution.

In various embodiments, the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.

In various embodiments, the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.

In various embodiments, the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In various embodiments, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

In various embodiments, the nonwoven material comprises fibers of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them.

In various embodiments, the method further comprises assembling the at least one composite layer with at least one inner layer and at least one outer layer, such that the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.

In various embodiments, each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed of lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven material.

In various embodiments, the method further comprises applying the solution to the exterior surface of the at least one outer layer for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from loosely sitting on or penetrating through the at least one outer layer.

In yet another aspect of the invention, the composition used in a multifunctional face mask for trapping and/or deactivating one or more of airborne virus, bacteria, pollen particles and hazardous chemicals comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them.

In various embodiments, the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.

In various embodiments, the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.

In various embodiments, the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.

In various embodiments, the cations in the anti-coronavirus salts being mixed in the adhesive(s) comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.

In certain aspect of the invention, the method of manufacturing a new type of a face mask, comprises turning each of two outer layers of flexible nonwoven material surface to be not only super-hydrophobic via coating the surface with an FDA-proven, skin-friendly, and biosafe organic substance of many types, but also electrostatically charged via wrapping the nonwoven material with an electrostatically charged, food-grade or food-safe plastic wrap; turning a middle layer of the nonwoven material to be super-hydrophilic and adhesive via coating the nonwoven material surface with a food-grade substance of many type, and be antiviral and antimicrobial via mixing with one of many types of FDA-proven antiviral substances; integrating the two outer- and one middle-layers into one composite that is further folded, or glued, or stapled into the face mask-like shape and size, and then attached with two elastic strings to finish the device (called QuMask); and tailoring and stitching the device into the semiconductor industry cleanroom-style protective suit that can maximally protect healthcare practitioners including nurses and medical doctors.

In some embodiments, the device is a new product made of three layers of nonwoven materials, each being surface-coated with one or several concertedly integrated functional substances and/or material that FDA-proven and food-safe, which is ideal to meeting the national and international URGENT need for effectively fighting the worldwide coronavirus outbreaks in these days.

In some embodiments, the nonwoven materials can be obtained off-shelf, i.e. immediately and sustainably available in the market worldwide especially in North America, and are made of natural, strong, long, lint-free, biosafe/biocompatible, inexpensive and biodegradable fibers from plant sources of many types.

In some embodiments, the middle layer being surface coated with a polysaccharides and/or oligosaccharides that can take the moisture from air and/or exhale breath to activate and maintain its adhesiveness for trapping, masking hence deactivating the airborne viral, bacterial, and pollen particles and airborne hazardous chemical, in which the trapping coronavirus virus particles is based a strong chemical bonding affinity between the adhesive and the coronavirus surface spikes.

In some embodiments, the method further comprises mixing one of many types of FDA-proven antiviral and/or antimicrobial chemicals into the organic substance, in order to further deactivate the viral and bacterial particles.

In some embodiments, the method further comprises coating the two outer layers of the nonwoven materials (each made of natural, strong, long, lint-free, biosafe/biocompatible, inexpensive and biodegradable fibers from plant sources of many types) with one of many types of FDA-proven organic substances (that are biosafe and friendly to human skin) to show a super-hydrophobicity that can discourage viral, bacterial, and pollen particles to stick onto and then penetrate through the outer layer.

In some aspect of the invention, the face mask, comprises at least three layers of inexpensive, off-shelf nonwoven materials with all surface functions being concertedly integrated for effectively fighting coronavirus, wherein the at least three layers comprise two outer layers and a middle layer disposed between the two outer layers.

In some embodiments, the two outer layers' surfaces are adapted to be super-hydrophobic and electrostatically charged for preventing the viral, bacterial and pollen particles from sticking on or penetrating through the outer layer.

In some embodiments, the middle layer surface is adapted to be super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate airborne viral, bacterial, and pollen particles and hazardous chemicals.

In some embodiments, the at least three layers are folded, or glued, or stapled into the shape and size of a face mask.

In some embodiments, the face mask further comprises two elastic strings attached on to the mask for the user to tighten the mask easily on her/his face.

In some embodiments, each of the at least three layers is formed by lint-free, natural, biosafe/biocompatible, low cost, and biodegradable fibers-turned nonwoven material.

In some embodiments, the middle layer is integrated with at least one of chemical bond, trap, deactivate airborne viral, bacterial and particles, and trap airborne pollen particles and hazardous chemicals, and with the two outer layers for effectively repelling and trapping the airborne chemicals and airborne viral, bacterial and pollen particles.

These and other aspects of the disclosure are further described below. Without intent to limit the scope of the disclosure, exemplary instruments, apparatus, methods and their related results according to the embodiments of the disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Moreover, certain theories are proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the disclosure so long as the disclosure is practiced according to the disclosure without regard for any particular theory or scheme of action.

The terms “QuSolution” and “QuMask” are trademarks of NuAirs Technologies, LLC, a Delaware limited liability company. The term “QuSolution(s)”, as used in the disclosure, refers particularly to a composition used in a multifunctional face mask for trapping and/or deactivating one or more of airborne virus, bacteria, pollen particles and hazardous chemicals, alternatively a solution of the composition according to various embodiments of the invention, while the term “QuMask(s)”, as used in the disclosure, refers specifically to the multifunctional face mask or face coverings according to various embodiments of the invention.

Various embodiments of the invention include formulations/compositions and methods for potential mass-production of a new multifunctional QuSolution for coating on surfaces of surgical, N95, and KN95 face masks to form the QuMask with each layer of off-shelf nonwoven materials integrated concertedly with several surface functions for effectively neutralizing virus including coronavirus. Embodiments also include the introducing of electrostatic charges from the plastic packaging material surface onto the QuMask surface for electrostatically trapping the airborne coronavirus particles. Embodiments further include the spray coating of the QuSolution onto personal face covering of many types for improving the anti-coronavirus efficacy.

In certain embodiments, the method of manufacturing the QuSolution comprises turning the food-grade and/or biodegradable adhesives, di- and tri-valent metals and anions, antifreeze agents, and moisture-holding substances as the components of the QuSolution(s) on the QuMasks and face-coverings. These components are FDA-okayed and/or generally regarded as safe (GRAS) substances, skin-friendly, and biosafe/biocompatible on the QuMasks and face-coverings.

In certain embodiments, the food-grade adhesives include, but are not limited to, sugar-, oligosaccharide- and polysaccharide-based biomolecules, and protein-based molecules such as glutens and collagens, etc. on the QuMasks and face-coverings. The food-grade adhesives can be in pure forms or mixtures, over a wide range of mixing ratios on the QuMasks and face-coverings.

In certain embodiments, the biocompatible and/or bio-degradable adhesives include, but are not limited to, the polyols and/or poly-alcohols, pure forms or in mixtures of the saccharide- and protein-based adhesives on the QuMasks and face-coverings.

In certain embodiments, anions of the anti-coronavirus salts include, but are not limited to, the mono-, di- and tri-valent anions such as Cl⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, and small organic acid-based polyatomic anions such as acetate, citrate, gluconate, lactate, oxalate, etc. on the QuMasks and face-coverings.

In certain embodiments, the cations in the anti-coronavirus salts include, but are not limited to, Zn²⁺, Ca²⁺, Mg²⁺, Ni²⁺, Ni³⁺, Co²⁺, Co³⁺, Fe²⁺, Fe³⁺, etc. on the QuMasks and face-coverings.

In certain embodiments, the salts can be pure form, or mixtures with a wide variety of mixing ratios, either with the same cation but different anions, or the same anions but different cations on the QuMasks and face-coverings.

In one embodiment, the salts and food-grade adhesives can be mixed over a wide range of mixing ratios on the QuMasks and face-coverings. In another embodiment, the salts and food-adhesives can be mixed with different antifreeze agents and moisture-holding salts over a wide range of mixing ratios on the QuMasks and face-coverings.

In one embodiment, the QuSolution can be water-soluble or water-dispersible, and can be washed away using water with or without using detergent(s), and using either hot water or cold water.

In one embodiment, the QuSolution is a mixture containing at least a food-grade adhesive (such as a saccharide-based GRAS substance), a coronavirus-neutralizing or coronavirus-deactivating agent (e.g., a water-soluble transition metals' di- or tri-valent cation, and a water-soluble inorganic or organic anion(s) of di- or tri-valences), some percentages of water molecules, some percentages of an antifreeze agent, and some percentages of a moisture-absorbent.

In certain embodiments, the QuSolution's active chemical filtrations for effectively trapping, deactivating, and neutralizing coronavirus particles are resulted from the coronavirus nanospike tip's S-protein being denatured and the nanospike body being wrapped and/or covered partially or completely by the QuSolution's component(s), quickly after the virus particles collide on the QuSolution-coated surface of face-coverings. The S-protein denaturation and the nanospike body wrapping/covering can quickly turn the coronavirus particle to be no longer functional i.e. no longer viral and/or no longer infectious.

In certain embodiments, the composition of the QuSolution is widely varied to fit the different needs under different conditions. One embodiment is for a cold winter use, i.e., difficult to be frozen to brittle powder falling off the surface or being sucked into wearer's mouth/nose during the normal wearing. The other embodiment is ideal for a hot summer use, i.e., difficult to be “melted” into liquid flowing and sticking on wearer's face/neck and clothes. The different embodiments make each's coating on the face-coverings to function over a longer time in cold winter or hot summer, both purposely and effectively balanced with the moisture from wearer's exhale breath.

In certain embodiments, the method of manufacturing the QuMask comprises turning the middle layer of the 3-ply nonwoven materials-based surgical mask into a disposable QuMask by coating the middle layer with the QuSolution(s) in which the coating thickness can be varied large over a wide range from nanometer-scales to micrometer-scales on the QuMasks, and realizing several functions concertedly to denature the coronavirus surface nanospike tip's viral protein called S-protein and to wrap the coronavirus nanospike surface with the adhesive to make the nanospike no longer functional, on the QuMasks.

In certain embodiments, the nonwoven materials can be made of fibers of synthetic (plastics) and natural (e.g. cellulose, wool, cotton, etc.) materials, in their pure forms and combined forms, for 3-ply, 4-ply, 5-ply and even more layers stacking together.

In certain embodiments, the fiber-lengths, fiber-diameters, and fiber-surface chemical functional groups can be varied largely over a wide range in either the pure form or the mixed forms.

In various embodiments, the method of manufacturing the QuMask comprises turning the QuMask inner and outer layers surface to be electrostatically activated, by transferring the electrostatic charges from the plastic packaging material surface onto the outer and inner layers surface on the QuMasks, and realizing the function for denaturing airborne coronavirus particle surface nanospike-tip's S-protein or the airborne bacterial cell's membrane proteins, quickly after the coronavirus and bacterial particles collide onto the inner and/or outer layers surface on the QuMasks.

In certain embodiments, the method for improving the woven and nonwoven textiles-based face coverings' anti-coronavirus efficacy comprises spray-coating the QuSolution on the surface of the face covering by wearer before wearing the face covering, and letting dry properly in air at ambient temperature and pressure, and turning the surface of face covering made of ordinary woven and nonwoven materials of many types to be much more anti-viral than the plain version with the coating.

Various embodiments include new formulations of the QuSolution involving substances that are FDA-okayed, or food-grade, or GRAS, or biodegradable, hand-washable, or water-washable, or soap-washable, or detergent-washable, or washer-washable, all as commodities available commercially. The methods of coating the QuSolutions, on all face-coverings, including spraying, brushing, dip-coating, etc. QuSolutions may be used as ingredients in other types of products, including those that are chemically produced and manufactured using the plastic materials such as the glove- and gown-based PPEs, and air filters of many forms made of nonwoven- or woven-fibers of synthetic, or natural, or synthetic-natural-hybrid materials.

In certain embodiments, the nonwoven and woven materials, made of natural or synthetic or natural-synthetic blended fibers of many types, can be flexible textile-like, or paper-like, or membrane-like, or filter-like, in many forms of pore-sizes, structures, thicknesses, and mechanical strengths.

In certain embodiments, the electrostatic charges on the inner and outer layers of large-scale manufactured disposable QuMask help trap the airborne particles and chemicals, such that the middle layer surface being coated with the QuSolution(s) at the manufacturing will be able to function over the longer wearing time for the wearer.

Various embodiments include new formulations involving natural plants-based fibers' self-assembly into the flexible textile-, or paper-, or membrane-, or filter-like nonwoven materials, and methods to manufacture and use such nonwoven materials, including the face mask of many shapes and thicknesses with concertedly integrated multiple functions that other face masks currently available in the market don't have.

Various embodiments involve a family of lint-free, natural, biosafe/biocompatible, low cost, and biodegradable fibers-turned nonwoven material of three layers, and new technological methods to use the three layers for large-scale manufacture of multifunctional face masks of new types in a variety of sizes and shapes. Embodiments also include the face mask integrated with at least a middle layer to chemical bond, trap and/or deactivate airborne viral, bacterial and particles, and trap airborne pollen particles and hazardous chemicals, and with two outer layers for effectively repelling and trapping the airborne chemicals and airborne viral, bacterial and pollen particles.

Various embodiments include a family of the QuSolutions for coating on a wide variety of materials through several different methods of applications and a family of QuSolutions for use as ingredients in a wide variety of materials that are manufactured using plastic materials.

Embodiments include the use of a family of the QuSolutions for coating on face coverings of both nonwoven and woven textiles made of all types of fibers, including lint-free, natural (such as cellulose, wool, cotton), biosafe/biocompatible, low-cost, and biodegradable fibers, and involve new methods for coating the QuSolutions on the face coverings in a large variety of sizes and shapes, for large-scale manufacturing and for personal applications.

Embodiments also include the use of a family of the QuSolutions for coating on surface of face-shields made of plastics of different types.

Embodiments also include the large-scale manufacturing of disposable QuMasks with a middle layer that has the surface coated with the QuSolution for chemically bonding, physically trapping, and actively neutralizing and disabling hazardous particles of airborne viruses, bacteria, pollens, dusts, and chemicals of many types.

Embodiments also include the use of one inner layer and one outer layer of the disposable QuMask for physically blocking and electrostatically trapping these airborne particles and chemicals. Embodiments also include the use of a plastic bag to seal a disposable QuMask at the manufacturing's packaging step, to transfer the electrostatic charges from the plastic surface to the disposable QuMask's inner and outer surface, and to keep the electrostatic charges on the disposable QuMask inner and outer surfaces in the plastic bag over a long shelf-life.

Embodiments also include the coatings or applications of the QuSolutions on other PPEs in addition to masks, such as being sprayed upon surgical gowns, shoe covers, hats, and other PPE and non-PPE items.

Embodiments also include the use of the QuSolutions as ingredients in a wide variety of materials that are manufactured using plastic materials, such as PPE gowns and gloves.

Various embodiments include a mixture integrating the water solvent with some water-soluble salts and some food-grade adhesives.

Various embodiments include the massively manufactured facemasks, each with the inner and outer surfaces containing the electrostatic charges and with the middle layer coated with the QuSolution.

The QuSolutions Compositions and Functions: The food-grade adhesive can be a food-grade substance of many types including polysaccharides and oligosaccharides. The food-grade adhesive can also be water-soluble proteins or biomolecules, such as glutens or collagens. All these food-grade adhesives are FDA-okayed GRAS substances. The food-grade adhesives can adsorb moisture from exhale breath or from air, to stay in the hydrated state, to show the super-hydrophilicity, and to activate the substance's adhesive property (like the sugary donut surface's sticky property) for gluing with and trapping the airborne bacterial, viral and pollen particles and airborne hazardous chemicals of many types.

The water-soluble salts can contain mono-, di- and tri-valent anions of monoatomic and polyatomic (small organic acid-based) anions. The different anions can determine the salts different water solubilities.

The di- and tri-valent anions can help quickly denature the coronavirus nanospike tip's S-protein or the proteins on bacterial cell membrane surface, can hold water from moisture in exhale breath to form hydrated anions and not to be easily dried in air over the time, all colorless, some's water-solubilities can be pH-sensitive depending on the cation(s), all low-cost and as the GRAS substances.

The water-soluble salts contain the transition metals' di- and/or tri-valent cations such as Zn(II), and other di- and tri-valent cations of both main-group metals and transition metals, etc.

The multivalent cations can help quickly denature the coronavirus nanospike tip's S-protein or the proteins on bacterial cell membrane surface, can hold water from moisture in exhale breath to form hydrated cations and not to be easily dried in air over the time, all colorless or with pale colors, some's water-solubilities can be pH-sensitive depending on the anion(s), all low-cost and as the GRAS substances.

The GRAS substances-based antifreeze agents can be food-grade polyols or poly-alcohols.

The moisture-trapping agent can be the salts' anions and cations, and can be the food-grade antifreeze agent, as mentioned in the above.

Methods for Coating the QuSolutions on the Disposable QuMasks at the Manufacturing: The high-throughput production lines for large scale manufacturing the disposable QuMask including the typical production lines for producing surgical, N95, and KN95 facemasks.

The high-throughput production lines for large scale manufacturing the disposable QuMask also including the typical production lines for producing coffee filter papers.

In any of the large-scale production lines, the QuSolutions will be simply sprayed as a mist uniformly onto the surface of the middle layer after the spool, and quickly dried properly (not too dry and not too wet) using a low-temperature how air blow or flash Infrared lamp heating right before the QuSolution-coated middle layer starts to stack with the outer and inner layer.

Methods for Introducing and Keeping Electrostatic Charges on the Disposable QuMasks: The plastic packaging film, like the plastic sandwich bag and kitchen food wrap, can transfer the surface electrostatic charges on the disposable QuMask's inner and outer surfaces. Once the disposable QuMask be wrapped or enveloped within two such plastic films, the electrostatic charges will stay on the disposable QuMask's inner and outer surfaces, over a long shelf-life.

Methods and Efficacy for Coating the QuSolutions on Face Coverings by Customers: the disposable QuSolutions of winter and summer recipes, each in a handheld spray bottle, can be simply sprayed onto the face-coverings of nearly any types.

The QuSolution coating can show much improved the efficacy in neutralizing and blocking the coronaviruses on the face coverings, contrasting largely with the plain face coverings with the QuSolution coating. The face covering's surface QuSolution coating and coronaviruses can be washed away, as mentioned in the above, and the face covering can be dried for use again with another spray using the QuSolution.

Various embodiments include a new integration of two super-hydrophobic outer layers with one super-hydrophilic middle layer of the nonwoven materials, from the natural plant fibers, into the form of face mask device. This new face mask device is referred to as QuMask.

Composition and Functions of the QuMask: Each of the two outer layers is a nonwoven material that is self-assembled by long, strong, lint-free, flexible, biosafe/biocompatible, low-cost, and biodegradable natural fibers from many types of plants, such as a wide variety of trees, hemp plants, to name but a few. Each of the two outer layers is treated purposely to be super-hydrophobic (i.e. water-repelling), via coating the nonwoven material surface with an FDA-proven organic substance of many types that are biosafe and friendly to human skin. The super-hydrophobic surface has a low friction coefficient (i.e. highly slippery) for effectively blocking airborne bacterial, viral and pollen particles and minimizing these particles' accident sticking on and passing through the outer layer.

In addition, each of the two outer layers is electrostatically charged, via wrapping each with an electrostatically charged plastic wrap, like the plastic food-warp, which can help trap and/or repel all airborne particles and chemicals with any surface portion being partially charged.

The two outer layers of the super-hydrophobic nonwoven material can help wick the moisture from exhale breath through the QuMask quickly, which helps keep the QuMask in a dry state over many hours of wearing under a wide range of temperature and humidity both indoor and outdoor. The dry QuMask can minimize the airborne bacterial, viral and pollen particles and hazardous chemicals of many types being trapped on the QuMask and then inhaled into the user's nose, throat, and lung.

The surface of the middle layer of nonwoven material is instead coated with a food-grade substance of many types such as polysaccharides and oligosaccharides that can adsorb moisture from exhale breath or air to stay in the hydrated state, to show the superhydrophilicity, and to activate the substance's adhesive property for trapping airborne bacterial, viral and pollen particles and airborne hazardous chemicals of many types that penetrate through the outer layer.

In particular, the chemistry principle of “like dissolves like” tells that the adhesive substance has an extremely high affinity for chemically bonding with coronavirus surface spikes, for maximally trapping coronavirus particles onto the middle layer surface, which is the unique and powerful function that all other face masks available in the market lack.

The food-grade adhesive substance is pre-mixed with one of many types of FDA-proven antiviral and antibacterial substance(s) that can help deactivate the virus and bacteria being trapped by and bonded on the food-grade adhesive.

This application describes the QuMask's concertedly integrated multiple functions, with the outer layers of the nonwoven material being superhydrophobic and electrostatically charged for removing airborne bacteria, virus and pollen from the breath-in air, and with the middle layer of superhydrophilic, adhesive, antiviral and antibacterial nonwoven material to help trap the bacteria, viruses, pollens and hazardous chemicals and to help deactivate the viruses and bacteria.

The face masks currently available in the market lack the QuMask's multiple functions, the multiple functions' organic integration, and multiple functions' concerted action for maximally protecting the QuMask users of all walks from being infected by the airborne bacterial, viral and pollen particles and many types of airborne hazardous chemicals. The current “state-of-art” technology on the antiviral face mask is coated with silver nanoparticles (i.e. colloids) that is toxic to human body and can pollute the environment to a hard- and expensive-to-remedy level quickly.

FIG. 1 shows schematic of multiple layers of a multifunctional face mask according to embodiments of the invention. Various embodiments of the QuMask material may be made by either making the nonwoven materials from the natural fibers much like the common practice in textile industry and paper mills, or simply using the off-shelf (i.e., immediately and sustainably available in the world market in both retail and wholesale quantities) nonwoven material. Via either way, the three layers of the nonwoven material after being pretreated can be folded, or glued, or stapled into the QuMask in a variety of shapes and size, and can be attached with two elastic strings for the user to tighten the QuMask on wear's face.

The QuMask products surface can be color- and pattern-printed to be fashionable, eventful, and cultural. The QuMask looks either brownish (made of unbleached fibers) or whitish (made of bleached fibers), to fit different users' different need. In addition, logos of any colors and shapes can be printed on the QuMask surface as needed.

The QuMask products surface can be coated with fragrances and aromas of many types in order to fit the needs of different users of all ages, genders, and ethnic and cultural backgrounds.

The QuMask products, including the outer- and middle-layers surface coatings, can last years to maximize the QuMask's shelf life. After use, the QuMask can be disposed as disposing many types of the typical face masks currently available in the market.

In brief, embodiments of the invention provide formulations and methods for potential mass-production of a new multifunctional face mask (i.e., QuMask) composing of three layers (i.e. triple shields) of inexpensive, off-shelf nonwoven materials with all surface functions being concertedly integrated for effectively fighting coronavirus. Embodiments include turning the two outer layers' surface to be super-hydrophobic and electrostatically charged for preventing the viral, bacterial and pollen particles from sticking on or penetrating through the outer layer, and turning the middle layer surface to be super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate airborne viral, bacterial, and pollen particles and hazardous chemicals. Further embodiments include folding, or gluing, or stapling the three layers into the shape and size of a conventional face mask, and attaching two elastic strings on to the QuMask for the user to tighten the QuMask easily on her/his face, like using a conventional face mask, which is viable to using worldwide nonwoven manufacturing infrastructures, such as those in the North America.

The foregoing description of the exemplary embodiments of the disclosure has been presented only for the purposes of illustration and description and is not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Many modifications and variations are possible in light of the above teaching.

The embodiments were chosen and described in order to explain the principles of the disclosure and their practical application so as to activate others skilled in the art to utilize the disclosure and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the disclosure pertains without departing from its spirit and scope. Accordingly, the scope of the disclosure is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.

Some references, which may include patents, patent applications and various publications, are cited and discussed in the description of this invention. The citation and/or discussion of such references is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference. 

What is claimed is:
 1. A multifunctional face mask, comprising: at least one composite layer comprising at least one layer of a nonwoven material and a composition coupled to the at least one layer of the nonwoven material such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals, wherein the composition comprises food-grade adhesives, biodegradable adhesives, antivirus salts' anions and/or cations, antifreeze agents, moisture-holding substances, or a combination of them.
 2. The multifunctional face mask of claim 1, wherein the food-grade adhesives comprise mono-, di-, oligo- and poly-saccharides-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms, or mixtures with a variety of mixing ratios, ranging from 99% to 1% for each components.
 3. The multifunctional face mask of claim 1, wherein the biodegradable adhesives comprise polyols containing small-chain carbohydrates, poly-alcohols including sugar alcohols containing one hydroxyl group attached to each carbon atom, mono- and di- and oligo- and poly-saccharides- or starches-based adhesives, protein-based adhesives including glutens and/or collagens, or a combination of them.
 4. The multifunctional face mask of claim 1, wherein the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.
 5. The multifunctional face mask of claim 1, wherein the cations in the anti-coronavirus salts comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.
 6. The multifunctional face mask of claim 1, wherein the antivirus salts comprising Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, are in pure forms, or mixtures with a variety of mixing ratios, either with the same cations but different anions or the same anions but different cations.
 7. The multifunctional face mask of claim 1, wherein the nonwoven material comprises fibers of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them.
 8. The multifunctional face mask of claim 7, wherein the fibers have fiber-lengths, fiber-diameters, and/or fiber-surface chemical functional groups that are variable over a range in either the pure forms or the mixed forms.
 9. The multifunctional face mask of claim 1, wherein the antivirus salts and the food-grade adhesives are mixed with the antifreeze agents, and the moisture-holding salts over a range of mixing ratios.
 10. The multifunctional face mask of claim 1, wherein the composition is coated on, and/or impregnated in the at least one layer of the nonwoven material.
 11. The multifunctional face mask of claim 1, wherein the at least one composite layer is adapted concertedly to denature nanospike proteins on the coronavirus surface and to wrap the coronavirus nanospike surface with the adhesives to make the nanospike no longer functional.
 12. The multifunctional face mask of claim 1, further comprising at least one inner layer and at least one outer layer, wherein the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.
 13. The multifunctional face mask of claim 12, wherein each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed by lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven materials that are synthetic or natural materials.
 14. The multifunctional face mask of claim 12, wherein the exterior surface of the at least one outer layer is adapted to be super-hydrophobic and electrostatically charged for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from sticking on or penetrating through the at least one outer layer.
 15. A method of manufacturing a multifunctional face mask, comprising: providing a solution containing a composition, wherein the composition comprises food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them; and applying the solution to at least one layer of a nonwoven material so that the composition is coated on, and/or impregnated in the at least one layer of the nonwoven material to form at least one composite layer therewith, such that the at least one composite layer is super-hydrophilic, adhesive, antiviral and/or antibacterial to trap and/or deactivate one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals.
 16. The method of claim 15, wherein said providing the solution comprises mixing the composition with water over a range of concentrations from 1% to 99%.
 17. The method of claim 15, wherein said applying the solution to the at least one layer of the nonwoven material comprises: spraying the solution to the at least one layer of the nonwoven material; or soaking the at least one layer of the nonwoven material in the solution.
 18. The method of claim 15, wherein the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.
 19. The method of claim 15, wherein the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.
 20. The method of claim 15, wherein the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.
 21. The method of claim 15, wherein the cations in the anti-coronavirus salts comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³⁺, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them.
 22. The method of claim 15, wherein the nonwoven material comprises fibers of synthetic and/or natural materials, in pure forms or mixed forms, and for 3-ply, 4-ply, 5-ply, and/or more layers stacking together, wherein the synthetic materials comprise plastics, and the natural materials comprise cellulose, wool, cotton, or a combination of them.
 23. The method of claim 15, further comprising assembling the at least one composite layer with at least one inner layer and at least one outer layer, such that the at least one composite layer is positioned between the at least one inner layer and the at least one outer layer.
 24. The method of claim 23, wherein each of the at least one inner layer, the at least one outer layer and the at least one composite layer is formed of lint-free, natural, low cost, biocompatible and biodegradable fibers-turned nonwoven material.
 25. The method of claim 23, further comprising applying the solution to the exterior surface of the at least one outer layer for preventing the one or more of airborne virus, bacteria, pollen particles, and hazardous chemicals from sticking on or penetrating through the at least one outer layer.
 26. A composition used in a multifunctional face mask for trapping and/or deactivating one or more of airborne virus, bacteria, pollen particles and hazardous chemicals, comprising: food-grade adhesives, biodegradable adhesives, anions and/or cations of antivirus salts, antifreeze agents, moisture-holding substances, or a combination of them.
 27. The composition of claim 26, wherein the food-grade adhesives comprise sugar-based biomolecules, oligosaccharide-based biomolecules, polysaccharide-based biomolecules, protein-based molecules including glutens and collagens, or a combination of them, wherein the food-grade adhesives are in pure forms or mixtures with a variety of mixing ratios.
 28. The composition of claim 26, wherein the biodegradable adhesives comprise polyols, poly-alcohols, saccharide-based adhesives, protein-based adhesives, or a combination of them.
 29. The composition of claim 26, wherein the anions of the antivirus salts comprise mono-, di- and/or tri-valent anions, and/or small organic acid-based polyatomic anions, wherein the mono-, di- and/or tri-valent anions include F⁻, Cl⁻, Br⁻, I⁻, SO₄ ²⁻, NO₃ ⁻, PO₄ ³⁻, or a combination of them, and wherein the small organic acid-based polyatomic anions include acetate, citrate, gluconate, lactate, oxalate, or a combination of them.
 30. The composition of claim 26, wherein the cations in the anti-coronavirus salts comprise Mg²⁺, Ca²⁺, Sr²⁺, Ba²⁺, Al³′+, Sn²⁺, Bi³⁺, V³⁺, Cr³⁺, Mn²⁺, Fe²⁺, Fe³⁺, Co²⁺, Co³⁺, Ni²⁺, Ni³⁺, Cu²⁺, Zn²⁺, or a combination of them. 